Professional Documents
Culture Documents
K C (A), INC: Nstallation and Aintenance Anual
K C (A), INC: Nstallation and Aintenance Anual
COMPRESSORS
(A
MERICA), INC
INSTALLATIONAND
MAINTENANCEMANUAL
WARNING
BE SURE TO COMPLETELY READ AND UNDERSTAND THE
CONTENTS OF THIS MANUAL BEFORE ANY ATTEMPT IS MADE TO
INSTALL, OPERATE OR MAINTENANCE THIS AIR COMPRESSOR.
NOTICE
THE OPERATION OF A ROTARY SCREW AIR COMPRESSOR IS
INHERITLY DANGEROUS.
KOBELCO COMPRESSORS (AMERICA), INC. HAS MADE EVERY
EFFORT TO PROVIDE YOU WITH A SAFE AIR COMPRESSOR.
ONLY TRAINED PERSONNEL, WHO HAVE BEEN DESIGNATED,
SHOULD OPERATE AND MAINTAIN THIS AIR COMPRESSOR.
FAILURE TO FOLLOW THE ENCLOSED INSTRUCTIONS WILL
GREATLY INCREASE THE RISK OF BODILY HARM AND/OR DEATH.
A QUALIFIED INDIVIDUAL MUST INSPECT AND APPROVE THE
ELECTRICAL SYSTEM, AIR PIPING, FILTER ELEMENTS,
COMPRESSOR SUCTION/ DISCHARGE, GAUGES, VALVES AND
HOSING AND ANY OTHER COMPONENTS NOT LISTED THAT ARE
RELATED TO THE OPERATION OF THIS AIR COMPRESSOR.
DO NOT ATTEMPT TO BEGIN OR CONTINUE TO OPERATE THIS
COMPRESSOR WHEN THERE IS RELATED DANGER PRESENT.
ANY MODIFICATION TO THIS COMPRESSOR WITHOUT SPECIFIC
WRITTEN APPROVAL FROM THE FACTORY (NOT DISTRIBUTOR)
WILL VOID WARRANTY AND COULD GREATLY INCREASE THE RISK
OF INJURY.
Contents
GENERAL INFORMATION ......................................................................................... 1
General Safety ........................................................................................................ 1
Installation / Installation site..................................................................................... 3
Electrical .................................................................................................................. 5
Operation................................................................................................................. 7
Shutdown ................................................................................................................ 7
Shutdown Inspection ............................................................................................... 8
Lubrication ............................................................................................................... 9
Rebuilding ............................................................................................................. 10
Description of Components ....................................................................................... 11
Motor ..................................................................................................................... 11
Air End................................................................................................................... 11
Triple Lip Seal ....................................................................................................... 12
Intake / Volume Control ......................................................................................... 12
Air Filter ................................................................................................................. 12
Inlet Valve.............................................................................................................. 13
Shuttle Valve ......................................................................................................... 13
Primary Separator ................................................................................................. 14
Secondary Separator ............................................................................................ 14
Lubricant................................................................................................................ 14
Cooling System ..................................................................................................... 15
Analog / Digital Electrical Cabinet ......................................................................... 17
Instrumentation...................................................................................................... 19
Installation ................................................................................................................. 20
General.................................................................................................................. 20
Handling ................................................................................................................ 20
Location ................................................................................................................. 20
Foundation ............................................................................................................ 23
Ventilation.............................................................................................................. 23
Aftercooler ............................................................................................................. 23
Receiver ................................................................................................................ 24
Air Piping ............................................................................................................... 24
Electrical ................................................................................................................ 24
Maintenance ............................................................................................................. 26
How to decode the Model Number ........................................................................ 26
Schedule ............................................................................................................... 27
Inlet valve unload pressure regulator .................................................................... 29
Shaft Lip Seal / Shaft Wear Sleeve ....................................................................... 29
Motor Coupling Installation .................................................................................... 32
Replacing Air Filter ................................................................................................ 34
Replacing Lubricant (Oil) Filter .............................................................................. 37
Lubricant Sampling ................................................................................................ 38
Replacing Coalescing (Separator) Filter ................................................................ 40
Replacing Lubricant (Oil) ....................................................................................... 41
Servicing Scavenger Return Valve ........................................................................ 43
Lubricating the Motor ............................................................................................. 45
Adjusting Modulation ............................................................................................. 47
Microprocessor Error Codes.................................................................................. 49
Microprocessor Reference .................................................................................... 50
GENERAL INFORMATION
General Safety
The following is provided to protect the customer from severe personal injury,
dismemberment, death, property damage, fire or damage to the compressor. We cannot
cover all dangerous situations, thus all users must exercise caution and common sense.
All persons working on and operating compressor should only do so after reading this
entire manual.
Inspect compressor daily to insure proper operation. See section 4.1 for more
details.
Periodically confirm all safety devices are properly working. Properly trained
personnel only must do this. If not done properly severe bodily and property
damage could occur.
Never bypass, override, tamper or remove any safety device installed on the
machine.
Do not use the air from this compressor for breathing air. THIS UNIT DOES NOT
COMPLY WITH OSHA 29 CFR 1910 REGULATIONS.
Do not allow flammable, toxic, or corrosive gasses or dust to enter the air inlet of
the compressor or electrical devices.
Never remove, alter or deface any of the warning, danger or caution decals
applied to the compressor.
We shall not be responsible for any personal injury and faults / damage of the
machine resulting from modifications by the customer.
Strictly follow the local regulations and the safety standard established in the
field.
Use only KOBELCO parts. If not observed, it can cause malfunction and / or
failure.
Insta
allation / Installation site
T
Transfer
When moving the
e machine using a forkklift
or a cran
ne, protect the
t sound proof
p
enclosurre with a pa
added cloth or padding
g to
prevent damage.
d
Do no
ot drop the machine
m
orr carry it at a
slant of 45
4 or more
e when movving it.
In
nstallation Site
Th
his machine
e is designe
ed for indoo
or use only.
Do not
n install machine
m
outdoors or se
emi-outdoorrs.
Installation in
n a place exxposed to rain
r
or in a
humid basemen
nt can causse an electrric leak, dra
ain
and / or rust.
Installation in
n a place where
w
dust such
s
as iron
n
powd
der, paper pulp
p
or san
nd is lifted can
c cause lo
ow
insulation performance of electrical parts and ca
an
dama
age the roto
or.
Installation in
n the atmossphere conttaining toxicc
gas can
c cause deterioratio
d
on of lubrica
ant and
corro
osion in parrts.
Re
efer to the Installation Section of this manua
al
for greater deta
ail.
Do
o not install the machine near a work
w
place
wherre flame is used or the
e ambient te
emperature
e is
over 100 F (38
8 C)
Do
o not place
e flammable
e objects ne
ear the
mach
hine.
Elec
ctrical
Electric
E
W
Wiring
m electric
Qualified electricians must perform
wiring.
Leading into
o the powerr source sho
ould be don
ne
not to
o expose wiring.
w
Wirin
ng into the control
c
cabin
net requiress a protectivve bushing in the
throu
ugh hole in order to protect the wires.
w
E
Electric
leakk (Grounded
d), low insu
ulation
perfo
ormance, ovver current, short circu
uit,
incorrrectly phassed operatio
on and mallfunction of
the safety
s
devicces can pro
oduce sparkk in the
moto
or, wiring an
nd electric circuit.
c
Breaker
B
Use a grounded breaker for the powerr source in accordance
e with
the machine modell.
Do no
ot use the knife
k
switch without an
ny grounded
d breakers in
terms off protection..
In
nstallation
oval or mod
dification off the safety
Remo
device or
o any chan
nge in the set
s values can
c
cause an
a accident..
Any change
c
in the set value for the
electrica
al safety de
evices and operation
o
w
without
a safetyy device can
n abnormallly heat the
lubrican
nt to start a fire. Never change the
e set
value orr operate th
he machine without, orr use
modified
d, safety de
evices.
Ground
G
Connecct the groun
nd wire with
h the groun
nd terminal
(Marked with
w ground
d symbol) on the contro
ol panel.
Grounding
g must be in accordan
nce with all National an
nd
Local elecctrical code.
Consult a qualified
d electrician
n for detailss.
Operation
Dangerous
D
Objects
Do not put any infflammabless around the
e machine. Never
use an op
pen flame near the ma
achine.
The compressor can
c catch fire from work being ca
arried
out near the machine
e that produ
uces spark,, such as
welding.
Do not touch the exhaust
e
outtlet and the
e peripheral area
which are heated during the ope
eration of th
he compresssor
and could
d remain ho
ot even after shut down
n of the ma
achine.
This area could causse a seriouss burn.
Pressure
P
Operrate the machine within
n the limits
specified in this ma
anual.
Rotating
R
Po
ortions
en the powe
er is on, ne
ever touch the rotating
Whe
portion
ns even if th
he compresssor is stopp
ped.
ny maintena
ance needss to be perfo
ormed be sure
s
to
If an
disconnect and lo
ock out the main power supply.
Shuttdown
Parallel
P
Op
peration
Clo
ose the disccharge stop
p valve of the machine
e which is
stopp
ped and reliieve the sysstem pressure.
7
Long
L
Term
m Shutdow
wn
Turn off th
he power supply and close
c
the diischarge va
alve
off the comprressor.
Be sure to
o perform a start-up (to stabilized
d discharge
e
te
emperature greater tha
an 175) on
nce a month
h. This is
esssential to prevent russt in the com
mpressor and bearing
da
amage.
Shuttdown Ins
spection
Pressure
P
Be
efore inspeccting the co
ompressor, stop the co
ompressor and
a
turn off
o the main
n power sup
pply breake
er. Make su
ure no presssure
remains in the system.
Power
P
Sup
pply
Be
efore replen
nishing lubricating oil or
o inspecting the contro
ol
board
d, be sure to turn off all the comp
pressors pow
wer supply.
Re
emember the compre
essor is eq
quipped with an
autom
matic startt function and
a
may start at ANY
Y time.
Lubrrication
Mixing
M
Lub
bricants
nly the speccified lubricating oil. Ne
ever
Use on
mix oils of different brands
b
or tyypes.
oration, sho
ortage or em
mptiness off
Deterio
lubricant and
a poor lu
ubricant circculation ressulting
from high viscosity can
c abnorm
mally raise th
he
lubricant temperatur
t
re hot enoug
gh to start a fire.
Be sure to
o visually check the lubricant leve
el on
the lubrica
ant level ga
auge (locate
ed on the primary
p
lubricant separator)
s
and, if it is low, replen
nish or
change it.
Replenishm
R
ment
If the
e lubricant level is belo
ow the lowe
er limit whe
en in
operatiion, replenish the lubriicant.
Befo
ore replenisshment, be sure to turn
n off the po
ower
supply and stop th
he compresssor. Note that
t
the pre
essure
remain
ns in the oil separator for
f minutes after the
compre
essor is sto
opped. Makke sure no pressure
p
remains
in the system
s
befo
ore the lubrricant is rep
plenished.
Changing
C
Lubricantt
M
Maximum
se
ervice life off the lubrica
ant is 3,000
0
hourrs, though it depends on
o the operrational
cond
ditions. Be sure
s
to com
mpletely dra
ain oil lubriccant,
this included all tubing and
d coolers.
D
Deteriorated
d lubricant requires
r
imm
mediate and full
chan
nge.
Lu
ubricant de
eterioration will cause the
t deteriorration
carb
bon to adhe
ere to the se
eparator ele
ement. The
e
dete
erioration ca
arbon may be partiallyy heated up by
oxidation heat to
t start a firre and explode.
W
When
chang
ging the lub
bricant, be sure
s
to repla
ace
the lubricant filtter elementt.
Rebu
uilding
A overhaul should be
Any
b performe
ed every five
e
yea
ars, regardle
ess of operration hourss. At that tim
me,
cha
ange the ma
ain motor bearings
b
and
d clean the
e coil.
T power supply
The
s
musst be cut offf and locked
d out
to perform
p
an overhaul on
n this mach
hine.
10
Description of Components
Motor
The standard Kobelco Ka Series Compressor is equipped with an
industrial quality motor. The motor is suitable for service with 480 volts,
240 volts and in some cases as low as 208 volts with a standard three
phase 60 Hertz AC input.
The motors are equipped with a NEMA standard C-face. The C-face
is used to properly align the compressor with the drive shaft of the
motor.
15 30 HP compressor packages are equipped with motors that
have a dual shaft configuration. The auxiliary shaft is used to drive the
cooling fan and the motor has been designed to accommodate the
extra HP draw required by the fan.
40 & 50 HP compressors are equipped with a single shaft motor with
a secondary fan motor.
If the situation occurs where the motor needs to be replaced after the
warranty period expires it is not recommended to replace with a
standard motor. You will encounter a shorter motor life. Please contact
you distributor or the factory for further consultation.
Air End
The basic air compressor is a single stage, positive displacement,
lubricated rotary screw unit. The air end has been designed to provide
the user with years of reliable usage.
The air end utilizes the inlet valve to supply the user with air at a
volume equal to the demand, up to the maximum capacity of the
compressor. The inlet valve serves as a check valve when the
compressor shuts down, preventing back spinning of the rotors. It also
acts as a lubricant stop valve.
11
Air Filter
The air filter can be easily replaced and maintenance can be performed. The
element should be cleaned periodically and replaced according to the
Maintenance Guidelines section at the end of this manual.
12
Inlet Valve
The piston actuated intake valve is controlled in two ways. The first way is
known as modulation. The second is known as unloaded.
In modulation, the control pressure regulator control sends a variable pressure
to the inlet valve piston gradually pushing the piston up and in turn closing the
inlet valve. This reduced the amount of air ingested by the air compressor until it
equals the amount demanded by the plant. At that point the pressure remains
stable.
The unload state occurs only when the set pressure of the main operating
pressure switch is reached, the solenoid coil for the unload control is deenergized. When the solenoid is de-energized, the air pressure from the shop
line/ reserve tank is allowed to pass thru the solenoid and enter the pressure
regulator and have the pressure reduced to a minimum of 50 psig. When the air
exits the pressure regulator it enters the shuttle valve (or logic) circuit. When
the line pressure enters the shuttle valve, this pressure is greater than the
pressure of the control pressure regulator so the air is allowed to pass to the inlet
valve actuator piston forcing closed the air inlet completely. This will stop any
ingestion of air into the air end and stop any pressure from being built up.
Shuttle Valve
This fitting is not to be
confused with a union
fitting. This fitting is also
known as an Or Valve.
This fitting directs air pressure to the inlet
valve piston from whichever source has the
greatest pressure. The sources are either
from the modulation valve (Top of Fitting)
or the pressure regulator (Below Fitting).
13
Primary Separator
The primary lubricant separator is an ASME certified vessel. The vessel has
been designed specifically for the KA series air compressor. NO
MODIFICATIONS OF ANY KIND SHOULD BE MADE TO THIS VESSEL. This
includes, but is not limited to; welding of any kind to the exterior or interior of
separator or taping addition holes. Any modification to the separator will void all
warranties implied or expressed.
Do not exceed rated pressure or temperature rating of the separator. The
standard rating is 200 PSIG at 250F Maximum continuous operation.
Secondary Separator
Kobelco KA series uses a spin on type secondary element. This element is of
a one-piece construction and is not cleanable. The element should be replaced
every 3000 hours of operation and differential pressure checked every lubricant
change. See Maintenance Guidelines towards end of manual for maximum
differential pressure.
The separator element should be replaced first if the unit fails to reach normal
operating pressure.
If the element is not maintained properly the element in the separator could
rupture and cause excessive downstream lubricant carry over.
The element uses a scavenger tube to return the captured lubricant back to
the air end. The tube is adjustable up and down and should be positioned off
the internal bottom of the element. A check valve is placed in line between the
filter and air end. This allows the scavenged lubricant to return to the compressor
under normal operation. When the compressor changes to the unload state, the
check valve stops the oil that is under high pressure from entering the dry side of
the element. If the check valve is removed this will cause a high amount of
lubricant to enter the air lines and could possibly permanently damage the
element.
Lubricant
The compressor is initially filled with one of Kobelcos Kobelube lubricants.
14
KA15
3.5
KA20
3.5
KA25
3.5
KA30
3.5
KA40
5.5
KA50
5.5
Cooling System
The cooling system consists of the following components:
Fan
Thermostat
15
Lubricant Filter
Connecting tubing
Pressure from the primary oil reserve tank causes the lubricant to flow through
the system to the lower pressure injection point in the compressor.
During normal operation the compressor lubricant passes from the primary
reserve tank thru the lubricant filter then into the thermostat housing. During cold
starts and warm up the thermostat opens a bypass port in the thermostat housing
and will cause the lubricant to partially bypass the heat exchanger. This brings
the lubricant up to operating temperature quicker. Once the lubricant is up to
operating temperature the thermostat closes the bypass port and causes the
lubricant to have full flow through the heat exchanger.
The lubricant filter is of the spin on type and should be serviced in accordance
to the Maintenance Guidelines section in the rear of the manual.
A drain valve is supplied for periodic fluid sampling, draining accumulated
condensate and drainage of lubricant for maintenance.
Cooling
System
16
Automatic Mode
In this mode the compressor will start compressing air until the line
pressure reaches the pressure set by the main operating pressure
switch. Once pressure switch has been triggered, three operations
occur simultaneously.
The unload solenoid valve de-energizes and allows line pressure to
enter the pressure regulator. Once the line pressure is regulated to 40
PSIG the air then enters the inlet valve which causes the air for the
rotors to be cut off thus the compressor can no longer produce
compressed air.
The sump blow down solenoid valve is de-energized which allows
the sump cavity to blow down to atmospheric pressure (0 PSIG).
This reduces the amount of back pressure the screw rotors have on
them. Energy consumption is reduced to about 20% of full load. The
unique design of the Kobelco Air End allows oil flow to occur even
without sump pressure.
Shut down timer is activated (This determines the amount of time
after system reaches unload condition for the motor to shut off.).
If there is no demand on the line and system maintains unload
condition for the amount of time set on the shut down timer, then the
power to the motor(s) will be cut off. Once there is a demand on the
system and the pressure is reduced to the set load setting point, three
operations occur simultaneously.
1. The unload solenoid valve is re-energized and line pressure is
terminated at solenoid valve body. The air trapped inside the
inlet valve is then released to atmosphere, allowing the inlet
valve to return to load condition.
17
Run Mode
In this mode the compressor will start compressing air until the line
pressure reaches the pressure set by the main operating pressure
switch. Once pressure switch has been triggered, two operations occur
simultaneously.
The unload solenoid valve de-energizes and allows line pressure to
enter the pressure regulator. Once the line pressure is regulated to 40
PSIG the air then enters the inlet valve which causes the air for the
rotors to be cut off thus the compressor can no longer produce
compressed air.
The sump blow down solenoid valve is de-energized which allows
the sump cavity to blow down to atmospheric pressure (0 PSIG). This
reduces the amount of back pressure the screw rotors have on them.
Energy consumption is reduced to about 20% of full load. The unique
design of the Kobelco Air End allows oil flow to occur even without
sump pressure.
The motor(s) will continue to run without shutting down. Once there
is a demand on the system and the main operating pressure switch
reaches the low setting point two operations occur simultaneously.
1. The unload solenoid valve is re-energized and line pressure is
terminated at solenoid valve body. The air trapped inside the inlet
valve is then released to atmosphere, allowing the inlet valve to
return to load condition.
2. The sump blow down solenoid valve is re-energized which closes
the open port and will cause the system to start building pressure.
18
This cycle will continue as long as the main switch is placed in the
Run mode.
Instrumentation
Line Pressure Gauge
Line pressure refers to the pressure AFTER the minimum
pressure check valve. This pressure is continuously monitored. This
is the pressure the main operating pressure switch / transducer
monitors.
19
Installation
General
Upon receipt of the compressor, be sure to completely inspect
machine for any signs of possible shipping damage. The carrier
should be immediately notified of damage or missing parts. Care must
be exercised when transporting or moving the compressor to avoid
damage to the unit.
Handling
The compressor base is equipped with slots for forklifts. These
slots should also be used when moving the compressor with an
overhead crane. Use spacers and spreader bars to avoid damage to
the compressor and to keep it balanced.
Location
The unit should be installed indoors in a clean, dust free, moisture
free, and well ventilated environment.
Process gasses or chemicals ingested in the compressor may react
with the lubricant or materials in compressor and significantly reduce
life. Avoid placing compressor anywhere near non-air vapors.
The unit must be protected against freezing and excessive ambient
temperatures. Failure to properly protect the machine may result in
catastrophic failure of components.
For ease of maintenance provide ample clearance around the
compressor that is clutter free. It is recommended to have at least four
feet in front of the compressor and a minimum of three feet on both
sides and rear. See the following illustrations for specific minimum
work envelopes.
20
21
22
Foundation
The compressor does not require a heavy foundation. To prevent
vibration the compressor should be supported at all base bolt
locations on a level surface. The mounting bolts must be carefully
mounted to prevent distortion of the compressor base. Do not weld on
compressor, cabinet, or base as it could cause damage to bearings,
electrical and other mechanical components and will void warranty.
Ventilation
The compressor must be located in a clean, cool and dry source of
air for the inlet filter and cooler. Since the compressor is air-cooled it
requires a large amount of cooling air to reject the heat loads. The
compressor must not be operated at full load for extended periods of
time in ambient temperature greater than 100 F (38 C).
If required, contact your distributor for air flow and heat rejection
numbers of your model.
Aftercooler
Moisture is removed from the compressed air by the Aftercooler,
which is installed between the minimum pressure check valve and the
air receiver or plant air system piping.
(If equipped) A moisture separator with an automatic moisture drain
is installed between the aftercooler and receiver tank. It is
recommended that the drain condensate be recovered and processed
to clean or recycled.
(If equipped) An automatic drain system is supplied on Kobelco
receiver tanks. If a drain is not installed the air capacity of the receiver
tank will decrease as it fills with water.
Do not dispose of compressor condensate in any manner other
than that approved by your local regulations.
23
Receiver
The compressor must be installed with an air receiver tank. It can
either be base mounted or a separate tank. Without an air receiver tank
the compressor will experience short cycle times with a higher amount
of oil carry over and may cause shorter motor life.
See specifications in the rear of this manual for recommended pipe
and air receiver sizes for your model.
DO NOT connect the KA SERIES compressor on the same line as a
reciprocating air compressor without an inline check valve on the
discharge of the Kobelco machine. This includes the air receiver tank.
The pulsations generated by the reciprocating compressor will cause
erratic behavior of the KA series compressor.
Air Piping
A minimum of schedule 40 pipe size is recommended for the KA
series compressors. See specifications in the rear of this manual for
recommended diameters.
Care must be taken to avoid placing a strain or bind in the piping
when connecting. If piping is subject to vibration from an external
source, flexible connections must be used.
NEVER USE PVC, PLASTIC, RUBBER HOSE OR SOLDERED JOINTS IN
THE AIR SYSTEM.
Electrical
General
A properly sized fusible disconnect is to be provided and sized by a
qualified electrician.
All internal control wiring has been done at the factory. A qualified
electrician should do all additional wiring in compliance with OSHA,
NEC and any other applicable local electrical code.
24
Motor Wiring
After the electrical wiring has been completed, it is necessary to
check the rotation of the main motor and fan motor (if equipped). This
can be done by intermittently jogging the run / off switch on the control
cabinet. There is a directional arrow riveted to the coupling cover that
indicates the direction of the shaft rotation. Fan should already be set
from the factory to follow correct motor rotation, however the fan
should always blow in the up (updraft models) direction or out (inline
models)direction.
25
Maintenance
How to decode the Model Number
26
Schedule
DAILY INSPECTION / SERVICE
WEEKLY SERVICE
Open the safety release valves at least once a week to make sure there is no
blockage or obstruction that could cause this safety feature not to properly
function.
27
28
29
for wear / leakage every 1 year of service. It is strongly recommended that the
shaft sleeve and shaft sleeve o-ring are replaced when the lip seals are replaced.
This will prevent premature wear on the new lip seals being installed.
When to Replace Shaft Sleeve:
Surface of sleeve has cracks, rust, wear grooves or any other visual
defects.
There is lubricant around the drive shaft which would indicate either a lip
seal failure or a shaft sleeve o-ring failure.
Consult Kobelco when it is time to replace the seals for replacement manual.
30
Replacement parts needed for lip seal and shaft sleeve replacement are
as follows:
20 Hp & 40 Hp Air End
Part
Number
QTY
DESCRIPTION
K55320088
K55340015
K55340018
K55310078
1 (optional)
K55320099
1 (optional)
QTY
DESCRIPTION
K55320088
K55340016
K55340019
K55310079
1 (optional)
K55320099
1 (optional)
QTY
DESCRIPTION
K55320088
K55340015
K55340018
K55310078
1 (optional)
K55320099
1 (optional)
31
Gently slide the motor coupling onto the drive shaft of the compressor.
o Note: If coupling does not slide on easily, remove and re-check for
contamination. Do not use a hammer or similar tool to force the
coupling onto the shaft. This could cause galling on shaft and
coupling, which will impede future assembly and may damage the
bearings and bearing pre-load spring.
Hand tighten the coupling retainer, lock washer and bolt (See above
Illustration) to the compressor shaft.
o Do not reuse lock washers.
Using a 17mm socket and torque wrench, tighten the coupling bolt to
35 Ft/lbs of torque. This step will apply the correct amount of preload
on the drive rotor bearing.
Motor Side
Remove any dirt and debris from the drive shaft of the motor and center
bore of the motor side drive coupling.
Remove any burrs from motor shaft and center bore of motor coupling.
32
Apply a thin layer of anti-seize lubricant on both the motor shaft and on the
inner bore of the motor coupling.
Gently slide the motor coupling onto the motor shaft. (Do not tighten bolts)
o Note: If coupling does not slide on easily, remove and re-check for
contamination. Do not use a hammer or similar tool to force the
coupling onto the shaft. This could cause galling on shaft and
coupling, which will impede future assembly.
Reattach the compressor onto the c-face of the motor using the (4) -13
bolts & (4) lock washers tightened to a torque of 70-90 Ft/lbs.
Confirm that there is at least 0.060 clearance between the motor coupling
and spider.
33
Primary
Filter
Filter
Service
Cover
Evacuator Valve
Using a soft rag, remove all the dust and debris from the inside surface of the
housing. Be careful not to introduce contamination into the outlet tube.
NOTE FAILURE TO DO SO MAY CAUSE CONTAMINATION TO BE
INTRODUCED TO THE SEAL AREA OF THE PRIMARY FILTER
DURING REINSTALLATION, CAUSING A LEAK. LEAKS RESULT IN
HIGHER RESTRICTION OF THE SAFETY FILTER AND SHORTEN
FILTER LIFE.
34
The safety filter should be changed every 3rd primary filter change out.
NOTE IF THE SAFETY IS NOT INSTALLED PROPERLY, IT MAY
ATTACH ITSELF TO THE PRIMARY FILTER UPON REMOVAL.
o Dust from the primary filter may be evident on the safety filter. This is
normal. At each 1st and 2nd primary filter change, check safety filter for
damage. If damaged, replace. Also check to ensure the safety filter is
properly seated in the housing. It should fit snugly inside the outlet tube.
Continue pushing the filter into the outlet tube until it stops.
Before installing a new primary or safety filter, inspect it carefully. Visually chaeck
for any voids, cuts, tears or indentations in the urethane-sealing surface. If your
check reveals damage, do not install the filter.
Refasten latches to secure cover. Make sure that latches penetrate the slots in
both the body and the cover.
35
Inspect and tighten all clamps, bolts and connections in the entire air intake
system. Check for holes in tubing, and repair if needed. If the Vacuator Valve is
damaged, replace.
36
Replacement of the lubrication filter should be done when one or more of the following
conditions are met, whichever comes first.
Horsepower
15, 20 & 25 Hp
30, 40 & 50 Hp
KP-CE-022
KP-CE-024
37
Lubricant Sampling
Tools Required:
o Kobelco Oil Sample Kit
o Small drip pan
o 3/8 Hex wrench
To ensure the five-year warranty, the compressor lubricant must be sampled and
tested every 1,000 hours of operation or every year depending on what comes first.
How to Sample
Slowly loosen and remove vented lubricant fill cap to insure pressure is
removed from separator vessel.
Slowly open ball drain valve on bottom of separator to drain a small amount
(approx. 1/4 cup) of lubricant into your drip pan to prevent contamination of the
lubricant sample and to drain possible condensate.
The sample can be taken when the lubricant filter is changed. The technique to
sample the oil is the key to successful analysis. With lubricant analysis you will have
insight to both the condition of the lubricant and the compressor. Do not sample
while compressor is running.
38
Take the sample from the same location and in the same manner each time.
This will insure repeatability of the test results.
Fill the sample bottle with lubricant from the center of the reservoir by removing
the oil fill cap and using a vacuum gun and tubing.
Be careful not to contaminate the sample with airborne dust particles. Carefully
and quickly cover the lubricant sample bottle.
Sample kits can be obtained from your authorized Kobelco distributor or directly
from Kobelco Compressors (America), INC.
Hours on machine.
Fill out information data sheet as completely as possible. Mail both completed
data sheet and filled sample bottle in the provided mailer. Fill out return address on
mailer and send to the address on the mailer with the appropriate postage affixed.
When the testing is finished, a lubricant analysis report will be sent to you. There
may be a nominal charge for this service.
39
Examine scavenger tube for signs of damage. Confirm end of tube is clear of
contamination.
Horsepower
15, 20 & 25 Hp
30, 40 & 50 Hp
KP-CE-018
KP-CE-020
40
Maximum Hours
Kobelube 46
8000
Kobelube 32
8000
Kobelube FG
3000
Kobelube Extra
10000
NOTE: The above time are based @ 190 F lubricant temperature. For every 10F
temperature rise, the lubricant life is reduced by 2000 hours.
Remove contaminates from around the oil drain plug, lubricant filter and
lubricant fill plug.
41
o Note: The fill cap has a pressure relief hole. If there is pressure in the
separator, you will feel or hear the air escaping once the cap is loose.
If you feel or hear the air, immediately retighten the cap and wait for
the pressure to finish bleeding to atmosphere. If the pressure does not
drop, examine the compressor to determine the problem and fix prior
to changing lubricant.
Connect a flexible drain hose with a M-NPT fitting on the end, to the drain
ball valve.
o If a tube is not available install a drain pan under valve.
Restart Compressor.
operation. If lubricant level is not visible, immediately stop the compressor and
add appropriate lubricant.
42
Scavenger
The scavenger return valve should be cleaned (or replaced if needed) every 1000
hours of operation. This will help insure low lubricant carry over.
Make sure all pressure has been removed from the connecting air lines and
sump tank.
Lock machine power out at main power source according to OSHA, NEC and
local codes.
While holding the top hex (that has the pipe nipple going into the compressor)
with a wrench loosens the lower body with another wrench.
With the wrench still on the top hex of the fitting attach a wrench to brass sleeve
just below the filter screen of the valve.
43
o CAUTION- This is spring loaded and contains small parts. Care must be
taken when this unit is disassembled to prevent losing parts.
Clean ball bearing and Viton bearing seat with soft cloth.
Clean orifice (in top part of illustration) with a mild solvent and compressed air.
44
Check filler and drain holes for blockage and clean as necessary.
Add proper type and amount of grease. See the relubrication time intervals
table for service schedule and relubrication amounts table for volume and
grease required.
Wipe off excess grease and replace filler and drain plugs.
Time Intervals
15, 20,
Service Condition
25HP
30, 40,
50HP
Standard
2 years
6 Months
Severe
1 year
3 Months
Lubricant Amounts
Volume cu. In. (fluid oz.)
46
50HP
1.25 (0.69)
1.50 (0.83)
Adjusting Modulation
It is very important that this valve does
not get painted or covered with any foreign
substance. There is a pilot hole near the
screw adjustment that MUST NOT BE
TAMPERED with or modified.
The modulation valve must be adjusted
whenever the unload pressure is modified.
The valve is designed to operate in a 6
psi band. This means the valve will
modulate the inlet for 6 psi before the inlet
valve is completely closed and no longer
allowed to build pressure.
For most efficient operation, the modulation range should be set to start 5 psi before
the set unload pressure (See MOD1).
If modulation range is set too high, the compressor will not operate as efficiently as
possible or will operate as a
load/unload compressor (See MOD2).
If modulation is set too low, the
compressor will not unload and will
have excessive noise and vibration
(See MOD3).
To increase modulation range, turn
the adjustment screw clockwise.
To reduce modulation range, turn
the adjustment screw counterclockwise.
NOTE: LOCKNUT MUST BE
TIGHTENED AFTER ADJUSTMENT.
47
48
Er:0080
Er:2118
Er:2128
Er:2138
Er:3123
49
Micrroprocess
sor Referrence
PASS
S CODE: 0009
M
Menu
up / Plus
P
M
Menu
Down
n / Minus
R
Return
/ Entter
E
Escape
/ Cle
ear
S
Start
S
Stop
C
Clear
/ Rese
et
H
How
to Enter Pass Code
C
Prress both th
he plus and minus butttons at the same time. Use the plus or minu
us
bu
uttons to inc
crease or decrease the
e pass code value. When you ha
ave the desired
va
alue, press Return to move to ne
ext digit.
H
Hour
Mete
ers
H1 = Total Ru
unning Hou
urs
H2
2 = Loaded Hours
H3
3 = Generall Service Ho
ours
H4
4 = Lubrican
nt Service Timer
T
H5
5 = Lubrican
nt Filter Serrvice Timerr
H6
6 = Coalesc
cing Filter Service
S
Timer
R
Reset
Serv
vice Timerrs (P04)
1. Enter pas
ss code
2. Press Re
eturn Butto
on
3. Press Me
enu Down to Menu P04
P
4. Press Re
eturn Butto
on
5. Press the
e Menu Down until yo
ou see the timer
t
you would
w
like to
o reset.
6. To reset the
t timer, press
p
Returrn twice.
50
Time is in 24 hour
6. Press the Escape Button three times to return to main operating screen.
Pu = Unload Pressure
Pl = Load Pressure
8. Press the Escape Button three times to return to main operating screen.
51
Each fault item consists of the following: 1) The fault Code Number 2)
The Running Hours when Fault Occurred 3)The Pressure 4) The
Temperature 5) Real time Clock data. The Display will automatically
alternate between these values.
52
Electric Schematic
An electrical schematic was shipped with your machine. Consult the document
packet that was shipped with your machine.
If required, contact the factory for a replacement.
53
Specifications
Data / Dimensions
Minimum
Receiver Size
120
120
120
120
200
200
J525 Hydraulic
Tube
1
1
1
1
2
2
This sizing is based on .5psi pressure drop per 100 feet of pipe at 100 psig operating
pressure.
Grade
5
5
5
5
54
Flow Diagram
55
Troubleshooting
Machine Will Not Start
Cause
Correction
Replace fuse.
Reset overload.
Power failure
Faulty Transformer
Unit locked up
Defective sensor
Low Voltage
56
Unscheduled Shutdown
Cause
Correction
Power failure
Replace.
temperature
Correct cause of the overload condition and press
Thermal overloads tripping
Low Voltage
57
Correction
Faulty motor
setting
accordingly
Correction
Drain lubricant to recommended level
lubricant separator
Clogged scavenger line
Incorrect Lubricant
58
Correction
Replace element. Make sure filter seals against
inlet valve.
Lubricant breakdown
Water in lubricant.
Contaminated lubricant
59
Correction
Drain lubricant to recommended level
lubricant separator
Clogged scavenger line
60
Correction
Check lines for leaks
lines
Plugged air filter
correctly.
Inlet valve not fully open
Repair or replace
valve
Excessive Demand
Restriction in system
Replace element.
Correction
Readjust main air pressure switch to desired
pressure. Replace if defective.
Check blowdown solenoid valve. Clean valve,
blowdown muffler and line. Replace if needed.
separator
Inlet valve not functioning
properly
Leak in control tubing
61
Correction
Check the location of cooler to make sure that
there is no restriction to free circulation of cooling air
through core. Be sure the discharge cooling air is not
being recirculated into either the compressor inlet or
the cooling core.
reservoir
Clogged lubricant filter
Replace element
cooler passages
Improper lubricant
Replace Valve
Faulty gauge,
62
Correction
System Contamination
Replace indicator.
Lubricant breakdown
Correction
Use remote air intake to air filter.
contaminated environment.
Correction
Readjust main air pressure switch to desired
pressure. Replace if defective.
See "Inlet valve not opening or closing in relation
to air demand" section of this troubleshooting guide.
Determine cause of contamination. Replace
separator element.
63
Correction
Readjust main air pressure switch to desired
pressure. Replace if defective.
assembly
Faulty Solenoid
Excessive Modulation
Cause
Faulty inlet valve
Correction
Check for a "Sticky" valve. Repair or replace as
needed.
64
Correction
Provide increased volume by adding an air
receiver tank.
correctly or defective
Water in control system.
Excessive Vibration
Cause
Correction
65
KOBELCO
COMPRESSORS
(A
MERICA), INC
66